Process for cleaning pile and other fabrics



Patented Feb. 6, 1940 UNITED STATES PATENT OFFICE Nish A. Jamgotch,Minneapolis, Minn.

No Drawing. Application March 6, 1937, Serial No. 129,472

9 Claims.

This invention relates to improvements in the cleaning of pile and otherfabrics including carpets and rugs, and has for an important object toprovide a method for thoroughly cleaning any 5 grade of carpeting orother textile napped floor material in situ,-that is on the floor of thehome or oifice, without appreciable detriment to texture or color of thefiber.

The accomplished objects of the invention are 10 speedy and thoroughwashing and cleaning of pile fabrics on the floor of the home or offlceandtacked or untacked without shrinkage, without fading, withoutmechanical or chemical injury to pile or base, and without wetting thefloor,

15 nor an interposed carpet pad.

Heretofore, it has been common practice to clean carpets, rugs andsimilar textile materials in either of two well known ways. vOne wayinvolves the'removal of the carpet or rug from the floor and thenwashing the same in suitable apparatus, drying, and again sizing theback of the carpet or rug. This operation is expensive, necessitates theremoval ofthe carpet or rug from the floor, is injuriousto the materialin many in- 25 stances, and is objectionable from other standpoints.

The other method of cleaning carpets and rugs involves the use of amotor driven brush with a liquid detergent on the rug or carpet while itis in 0 position on the floor. Shrinkage of the material takes place inmany instances and results in distortion and tearing if the material isfastened in place, to say nothing of the wear on the nap of the materialby the brush.

A very important advantage in my process is that there is no shrinkageof the moistened material. 'In brush scrubbing of carpeting shrinkage isconsiderable.' Operating, for example, on a nine by twelve Wilton rug,the shrinkage in 40 length is from two and one-half to three inches andthe shrinkage in width is from one and onehalf to two inches. Where therug is fitted to the room shrinkage spoils the fit. If the rug is fittedand tacked to the floor and if an attempt 45 were made to wash it by theold methods, tearing would occur and the carpeting no longer fits theroom. K

The success of my method seems primarily to depend on application byspraying, and the use 50 of awater solution of a neutral detergentcompound, and the employment only of vacuum for the removal of thatsolution with its contained dirt or foreign matter. By my method all ofthe detrimental effects of wet-brushing are avoided,

55 soaking of the base of the carpet is avoided and air is suckedthrough the base threads of the carpeting from the floor side upwardlyalong the nap towards the outer terminals of said nap to obtain thoroughdrying. There is no violent brush-grinding of the nap, nor any folding,roll- 5 ing, tumbling or other handling of the covering such as isnecessary in the old schemes.

The common and frequent use today of the new patented types of twistedyarns adds to the difllculty of cleaning without detriment. I have.found that my process will wash the cheapest carpets with no appreciabledetriment, and a. special feature of the invention is that the carpetscan be washed in situ, that is, on the floor, and can be properly driedon the floor. This is a very important fe: ture. Heretofore, it wasalways necessary to take the carpeting oil of the floor, send it to thecleaners, clean it, return it and then relay it.

Of course it is well known to all carpet cleaners and probably to mosthousewives that home vacuum devices do not clean carpets, but only suckup the surface particles of dust or loose dirt, without removing thedulling and discoloring foreign incrustation on the fibers.Incidentally, with certain types of home vacuum machines which havebrushes combined with vacuum, much of the small amount of wool of somerugs is found in the bag of the vacuum cleaner. Brushes are detrimentalto all carpeting.

In a study of carpet wools, carpet fillers other than wool, and carpetcleaning, over a period of twelve years and by various washing tests onvarious carpets, I have proved by scientifically conducted tests,including careful microscopic examinations, color tests, etc., thatbrush scrubbing of a wet carpet is very detrimental and that the soakingof the entire carpet with water does not thoroughly remove the dirt, andleaves the carpet streaked and spotted after the operation.

My method consists in heating water to about 140 to 170 F. and,thenhighly atomizing the same (by adding hot air at the nozzle) and applyingthe atomized water in a fine spray, preferably avoiding deep penetrationinto the base. I next spray the carpet with a warm water solution of aneutral detergent compound, the spray preferably being of round form (asdistinguished from fiat) and the detergent solution being highlyatomized before application and being applied in the same manner as thewater. I next use a vacuum apparatus to remove the solution and itscontained dirt, and-if, as does occur in some cases, the rug has beenbadly spotted by use,

a second application ofthe detergent is made around these spots andvacuum is again used. All

treatments with detergent should be made be-- fore the acetic acid isapplied, as hereinafter described. I

After the vacuum removal of the detergent solution and dirt containedtherein, I then apply a highly atomized spray solution of acetic acid,or equivalent, the object of which is to thoroughly free the fiber andbase of any remaining detergent, the action being to effect a thoroughloosening of the soapy film, and to assist in drying. The drying actionof the acetic acid is an important feature, because by varying theamount or proportion of acetic acid, a greater or lesser degree ofdrying can be accomplished. This enables-me to wash carpets on the floorof the home. Of course, the use of vacuum and acetic acid results in theremoval of any water which may have entered the base material of thecarpet, but the liquids are ordinarily so controlled, by sprayapplication that penetration into or through the base material does notoccur. Generally there is no need for penetration nor is it advisablethat the liquids penetrate the base.

I next use the vacuum to finally remove'all liquid and to effectthorough drying of the material, and to remove any residual detergent.If desired the carpet may be repeatedly gone over with a vacuumapparatus. In drying carpeting on the fioor, the amount of acetic acidis generally increased to hasten drying, as well as to thoroughlyneutralize the previously applied detergent chemical.

The neutral character of the detergent or cleaning fluid is important,and specifically the use of this material as part of the-process isclaimed, although the invention as a process is broader than thespecific composition of the detergent used. The detergent material perse is covered in another application copending herewith.

In the preparation of the cleaning or detergent compound I use naturalraw bentonite, in powdered form of about 300 mesh. I add to and mix withabout 20 pounds dry weight or about 50' pounds wet weight of thebentonite about 5 gallons of heated water, preferably distilled water.This mixture is then heated in a closed vessel to about 190 F; and atthis temperature there is introduced into the closed receptacle about 55cc. of 56 percent water solution of acetic acid, which has a temperatureof about 150 F when introduced. About five minutes after theintroduction of the acetic acid the receptacle is opened.

After the bentonite-acetic acid product is cooled and filtered and afterit cools to a temperature of about 85 F., and preferably not less than70, six and one-half pounds of trisodium phosphate is added. A whipperor stirrer is then used and the substance is stirred for about four andone-half hours. During this stirring period I add one-half poundportions of soda ash every half hour, the total amount added being aboutfour pounds. At the end a very thick heavy mass is formed and i. istransferred to a storage compartment and quart portions ofdistilledwater are added, the total quantity added being about 20gallons, making about 38 gallons of the material in all. Under steam themass of non-alkaline bentonite forms a jell and the volume is increasedas much as ten times. Other substances can be used, such as whiting orchalk.

Into a separate open tank is now put about 50 pounds of commercial oliveoil foots. The foots havegone through a salting process in which aftereach salting the upper part of the tank in which it is contained isthoroughly cleaned with a fine screen, preferably 75 mesh. To the saltedolive oil is then added a solution of about one and one-half pounds ofdry lyein about one gallon of water, the water being 'added a little ata time. The addition of the lye to the oil is made at a temperature ofabout 400 F. Thereafter about two pounds of common salt is added over aperiod of four hours. The tank should be only about one-half full atsanytime. The object of the salt is to extract as much of the free alkali aspossible. The batch is now allowed to slowly cool (while being agitated)to a temperature of about 80 F. which ordinarily takes about 15 hours,and at this temperature of 80 about 100 pounds of distilled water isadded, about one gallon at a time. The final result is a neutral soapstock which is about 94 to 97.5 pure.

After salting the soap is added to the bentoniteacetic acid solution andthe whole is whipped for about 6 hours very slowly. Slow whipping isvery important. The whipper arm makes only about 15 to 20 turns perminute. After about 6 hours whipping, the product is dumped into alarger storage tank and for each part by weight of the compound there isadded two parts by weightof water. It is preferable to underwater, thanto overwater. More uniformity can be obtained by underwatering and theprocess can be more accurately controlled. After complete chilling thematerial is finally filtered, preferably in a pulp filter, and is thenbottled, in air tight containers. Before it is used one gallon isdiluted to five gallons of distilled water, and the water is preferablyhot and is added just before using.

Any preferred type of steamer can be used for heating the soft water andthe water is heated to a temperature of approximately 160 to 170 beforeit is atomized, and is applied as a spray in the first step of theprocess. A compression tank is used for the water and the air issupplied by a small apparatus delivering air at a pressure of 100 to 110pounds at the nozzle of the spray gun. A very fine spray is obtained,and should be obtained, and the spray contains about '70 to 75 percentof air.

This spray is so applied that most of it lies on the surface or upperpart of the pile. Most of the dirt 'or sticky substance is on thesurface of the pile and not on the base of the fabric. Usually thedetergent material is applied about three minutes after the applicationof water and air spray, and this liquid is also applied by air sprayingthrough the same atomizing nozzle which is used for the application ofthe water.

In less than about 2 minutes from the time of the application of thedetergent solution, penetration over the entire pile of the fabricbegins and extends to a depth of /8 to A of an inch.

In some instances it may extend to the base'and in fact I have foundthat bythis method the upper side of the base is cleaned and has theappearanlce of new carpet. After application of the solution the vacuumof course is used which neutralizing and drying, but antiseptic incharacter. If the spray antiseptic or neutralizing spray is applied tothe spots left on the carpet it will be difficult if not impossible toremove the spots thereafter. 'For this reason no spotting" should beattempted after the antiseptic or drying spray is applied.

The antiseptic or neutralizer is composed of about 65 percent of woodvinegar (acetic acid) about 2 percent of oxalic acid and about 5 percent of alum. This solution also acts as a cutting agent and cuttingagents of other kinds 'may be applied. As before stated the vacuum isapplied over the whole carpet following application of the cuttingagent, and warm dry air may be applied to hasten final drying.

The vacuum operation may in some instances be repeated to assist indrying and the carpet should be thoroughly dried. I have found that withthis process and the final application of warm air, the carpet isquickly dried.

In my process, all applications of liquid or chemical are applied byspraying which spraying is so controlled as only to thoroughly moistenthe pile. By spraying, the liquid is not onlynot driven through the baseof the carpet, but it is very uniformly applied. By my method a staircarpet can be successfully washed while on the floor while the usualpads remain beneath. And the same is true for rugs in homes where a padis interposed between the rug and the floor. Even needle-poinupholstered chairs can be cleaned by this method without removing theupholstering. And this is accomplished in part by careful control of thespray at reduced pressure, or by spreading or more finely atomizing.

The soft water, which can be obtained by the use of zeolite, is heatedto about 160 F., and is delivered at the nozzle at about 100 F. It hitsthe carpet at about 85 F. The air from the compressor tank may or maynot be heated but preferably is heated.

The soap compound is applied so as to hit the carpet at about F. andtheacetic acid should be at about a temperature of 70 preferably 60 when ithits the carpet. It may be said that the temperature range forapplication of the water and soap is from 60 to and the applicationtemperature for the acetic acid may range between 60 and 70. J

I have found operating with soap prepared without bentonite, andexperimenting with a nine by twelve rug, that the drying time is 45minutes longer than when bentonite is used and that under thoseconditions twice as much liquid is required. While I believe that myinvention is not entirely limited to the use of a detergent having anabsorbent incorporated therein, I consider such incorporation important.

Whatever compound is used it is preferred that it be washed out by Wateror by suitable chemical, and in my process the removal of moisture isaccomplished by vacuum. The use of acetic acid or its equivalent isadvisable to get the best results. That is, the use of acetic acid orsome equivalent chemical, so acting on the soap as to change itscondition to make it more easily removable with its contained dirt is ofgreat advantage.

An important point is to so operate as to substantially prevent wettingof the base of the carpet, but so that substantially the entire lengthof the pile is moistened (not soaked). I distinguish between wetting orsoaking and moistening. By the wetting I mean so saturating thecarpeting that there is decided volume of overflow onto and sometimesinto the base material. By moistening I mean an operation in which theliquid material is spread uniformly but somewhat lightly and so as notto be driven into or through the base material. It will be understoodthat most of the loose dirt is at or on the top which is caked with theforeign substances generally of gummy coal tar nature mixed with fineparticles of-sand or gravel dust, and sand and coarser foreign materialswhich has sifted through the pile to the top surface of the base isremoved by vacuum. It is therefore unnecessary and undesirable to wetthe base of the carpet.

In so far as I am aware this method is the only brushless method ofwashing for really cleaning carpets. The process is completely harmlessand I avoid a straight suction vacuum process with a motor driven brush.These motor driven brushes of vacuum machines have submitted modern typeof floor covering to a great deal of unnatural wear. Probably twice asmuch wear as from the ordinary foot pounding which occurs under normalconditions of use. The process is harmless, but speedy. The lightapplication of proper liquids uniformly without saturation, and the useonly of vacuum to remove moisture and the other gritty material from thepile and base is important.

I claim as my invention:

1. A brushless process for cleaning pile fabrics which consists inapplying a mist-like spray of water and air to the fabric pile inquantities insumcient to penetrate to the base of the fab.- ric to anyappreciable extent and to provide a surface of the base of the carpet.Itis the pile substantially continuous film of water over the surface ofthe fabric, then applying a liquid detergent as a mist-like spray to thefabric pile and in such quantity as not to materially wet the base ofthe fabric, and then removing the detergent and loosened dirt bysuction.

2. A brushless process for cleaning pile fabrics which consists inapplying a mist-like spray of water and air to the fabric pile inquantities insufficient to penetrate to the base of the fabric to anyappreciable extent, then applying a liquid non-neutral detergent as amist-like spray to the fabric pile and in suchquantity as not tomaterially wet the base of the fabric, then removing the detergent andloosened dirt by suction, then applying a liquid spray capable ofneutralizing any of said detergent remaining in the fabric, and thenapplying suction to remove the applied substance and dry the fabric.

3. A brushless process for cleaning pile fabrics a which consists inapplying a mist-like spray of water and air to the fabric pile inquantities insufflcient to penetrate to the base of the fabric to anyappreciable extent, then-applying a liquid alkaline detergent as amist-like spray to the fabric pile and in such quantity as not tomaterially wet the base of the fabric, then removing the detergent andloosened dirt by suction, then applying to the fabric a liquid sprayhaving an acid reaction, and then applying suction to remove the appliedsubstance and dry the fabric.

4. A brushless process for cleaning pile fabrics which consists inapplying a mist-like spray of water and air to the fabric pile inquantities intaining a soap base as a mist-like spray to the fabric pilein such quantity as not to materially wet the base of the fabric and ata temperature of about 80 when it reaches the fabric, and then removingthedetergent and loosened dirt by suction.

5. A brushless process for cleaning pile fabrics which consists inapplying a. mist-like spray of water and air tothe fabric pile inquantities insuificient to penetrate to the base of the fabric to anyappreciable extent and at a temperature of from substantially 70 to 90F. when it reaches the fabric, then applying a liquid detergentcontaining a soap base as a mist-like spray to the fabric pile in suchquantity as not to materially wet the base of the fabric and at atemperature of about 80 when it reaches the fabric, then removing thedetergent and loosened dirt by suction, then applying a liquid spraycapable of neutralizing any detergent remaining in the fabric, and thenapplying suction to remove the applied substance and dry the fabric.

6. A brushless prdcess for cleaning pile fabrics which consists inapplying a mist-like spray of water and air to the fabric pile inquantities insuflicient to penetrate to the base of the fabric to anyappreciable extent, then applying a detergent containing a soap base andbentonite as a mist-like spray to the fabric pile, then applyins aliquid spray of a substance which reacts with the detergent to decreaseits filming action,

and then applying suction to remove the applied substance and dry thefabric.

7. A brushless process for cleaning pile fabrics which consists inapplying a mist-like spray of water and air to the fabric pile inquantities insumcient to penetrate to the base of the fabric" penetrateto the base of the fabric to any appreciable extent, then spraying witha solution of a detergent containing a soap base in which bentonite andacetic acid are incorporated, then spraying on a substance whichcontains acetic acid and which reacts with the detergent to decrease itsfilming action, and then applying suction to remove the appliedsubstance and dry the fabric.

9. A brushless process for cleaning pile fabrics which consists inapplying an alkaline liquid detergent as a mist-like spray to the fabricpile and in such quantity as not to materially wet the base of thefabric and to provide a substantially continuous liquid film over thesurface of the fabric and at a temperature of about 80 F. when itreaches the fabric, then removing the detergent and loosened dirt bysuction, then applying a liquid spray havingan acid reaction and capableof neutralizing any detergent remaining in the fabric; and then applyingsuction to remove the applied substance and dry the fabric.

NISH A. JAMGO'I'CH.

